Safety cap



April 25, 1967 E. c. BULLARD y SAFETY CAP Filed June 1. 1965 FEW/G.

INVENTOR, UL L A20.

Eff/AN c. 5

United States Patent O 4 Claims. (Cl. 2-3) This application is a substitute of my prior application S.N. 206,273, filed lune 29, 1962, now abandoned.

The invention relates to a head protective device and particularly to a safety cap of unique and novel design for use by industrial, commercial workers and the like.

Those familiar with safety devices generally will understand that in industrial and commercial activities it is desirable that the worker utilize a suitable head protecting device to avoid accidental injury while engagedin his occupation. For example, telephone men frequently are required to enter rather tight crawl spaces and the like in homes or other buildings to accommodate service installation. While moving in these confined quarters, these individuals are frequently subjected to accidental bumps on the head which are not only personally irritating, but subjects such persons to potential injury. In other active professions such as for example, aircraft assemblers and service men, a high degree of mobility again in confined quarters is required. Here protective head devices also avoid injury due to accidental'head bumping or accidental contact with swinging beams, jibs, or other operating equipment.

While avoiding potential injury to the user, protective devices heretofore employed in the art have presented many disadvantages. Characteristically, the devices were composed of a hard shell which, though satisfactory from a safety standpoint, have been found to be uncomfortable and difficult to wear by the operator over an extended period of time. Furthermore, head gear of this prior art type has been found difficult to size properly and, accordingly, not readily adaptable to the varying shaped heads of individual workers. Users frequently complained of discomfort, headaches, and the like.

A specific disadvantage of the prior art protective head gear relates to the utilization of such equipment in connection with the service of aircraft. In aircraft and missile servicing, it is Well known that many highly sophisticated and volatile fuels are utilized. rThis type of fuel, because of its inherent volatility, provides an ever present danger of accidental re and explosion. The heretofore utilized hard plastic safety caps were found to be disadvantageous in that they tended to surface-store'static electrical charges much the same as an electrical condenser. Frequently, these electrical charges would be built up in a given head gear merely as a result of the frictional contact between the head gear and the surrounding air moving thereover. The hazard is obvious. The existence of suchY a static charge and the possibility of spark-to-ground in a volatile atmosphere is always present.

The present invention obviates all of the mentioned diiculties in that it provides a safety cap of unique design which initially is readily adaptable to head contours of varying form and, accordingly, extremely comfortable to wear. Further, the design employs a unique structural arrangement which positively prohibits the accidental storage of static charge thereon, yet offering a maximum degree of head protection required in many day-to-day occupations.

These and other objects and features of the invention will become apparent in the course of the following description and from an examination of the drawings, wherein:

FIGURE 1 is a top plan view of a typical safety cap constructed in accordance with the instructions;

FIGURE 2 is a top plan view of a half section of a cap similar to FIGURE l but with the cloth cap covering removed; and

FIGURE 3 is a vertical sectional, side elevational view of the cap shown in FIGURE 1.

Describing the invention in detail and directing attention to the figures, it will be noted that the cap arrangement comprises a central liner 2, said central liner 2 being generally cup-shaped, preferably to the general configuration of a human head. In the preferred embodiment of the invention, the liner 2 is made of a plastic material, it being found that a suitable type plastic known under the trade name Marlex is satisfactory for the functions hereafter described. The liner 2 is delineated by a lower edge 4, the edge 4 preferably falling in a uniform plane defining the lower terminus ofthe liner. In addition, the liner 2 is provided with a plurality of slots 6, 8, 10 and 12 formed therein preferably equal angular spacing around the entire periphery of the liner. It will be understood that, in the half section view of FIGURE 2, only four of the slots are illustrated, but that the other half segment of the cap is identical with that here illustrated, the slots 6 and 12 being partially shown. Each of the slots 6, 8, 10 and 12 break the lower edge 4 of the liner 2 and ex- I tend radially inwardly of the liner 2 as seen in plan view approximately two-thirds of the distance of the liner from lower edge 4 to the apex 14 thereof. It will be understood that the formation of the respective slots is an im.- portant feature of the invention and that the depth of the slots within the liner 2 may be of varying degree, it having been found that the approximate two-thirds distance mentioned provides a very satisfactory structure, both from the standpoint of wearer comfort and protection.

The liner 2 may further be provided with a forwardlyprojecting plastic visor 16, said visor 16 in the preferred embodiment being a separate plastic part and not integrally connected to the liner 2. However, if desired, the plastic visor may be connected in any suitable manner to the liner 2.

Adjacent the lower edge 4 of the liner 2, the latter is provided with a plurality of radially outwardly-projecting studs 18, 18, the studs 18 providing suitable means for attaching a cup-shaped formed cloth cover 20. The cloth cover 20 is formed to complement the general contour of the liner 2 and intimately overlie the upper surface thereof. The cloth cover 20 is further provided with snap fasteners 22 which may be of any conventional design and which claspingly receive the studs 18 on the plastic liner 2. In this manner, the cup-shaped cloth cover 20 is fxedly secured to the liner 2 and completely covers the upper surface thereof.

As an additional feature of the invention, the cloth cover 20 may be provided around its lower angular edge with a bead 24. The `bead 24 may be slightly tensioned within the cloth cover 20 so that it tends to snap-underlie the lower edge 4 of the liner 2 and retain the cloth cover on the latter uniformly around the entire lower periphery of the liner 2. The bead 24 may, of course, be stretched within the cover 20. Thus, bulges of the plastic liner 2 intermediate the snaps 22 are eliminated, thus enhancing appearance as welllas assuring complete cover age of the internal liner 2.

To provide uniform appearance and further to` completelycover all of the plastic liner 2, the cloth cover 20 maybe provided with an appropriate visor section 30, the latter extending downwardly over the surface of the plastic visor 16 and therearound upwardly as at 32 to cover the lower surface of the visor 16. The cloth visor segments 30 and 32, of course, may be sewn or otherwise iixedly secured to the cloth cover 20 in anyrconventional j manner.

To materially enhance the illustrated, it hasy been found desirable to provideon the inner side of the plastic'liner 2 and at the central dome thereof la suitable annular segment of cushion material 34 such as vsponge rubber or the like. The central segment 34 is provided with a pluralityof uniformly-radiating .cushion material 36, 36 extending therefrom and preferably underlying each of the'nrespective slots ,6', 8 and 12. An annularband of sponge material 38 is positioned on the inner surface of the liner 2 and 'immediately adjacent to the lower terminal edge 4 thereof. The radial spokes 36, 3,6 communicate with` the annular band 38, in association with the lcentral segment 34', provide an appropriate soft cushion to comfortably engage, the head of any wearer.

It will be understoodV that and 38 may be secured to the inner surface of the liner 2 in Vanyrsuitabl'e manner s-uchy as, for example, by utiliz'- ing an appropriate resin,

glue or the like. v y Y Considering for the moment the unique features and desirable advantages` of the structure just described, it will be Vunderstood that the provision of aplastic liner 2, when the safety cap is in/use, as Well as the employment of the cushion material on the Vundersurface of the liner 2, acts as a Vsafety member to resist virtually any normal accidental blow to the head ofthe wearer. 1t will also be noted that the plastic liner 2 uniformly covers virtually the entire Iupper portion of the Wearers head. In this manner, the desired protection is afforded for virtually allnormal occupational hazards. f l v As a particular feature of theY described arrangement, it Will'berecalled that the liner 2 is `providedwith a plurality4 of segments 40, 40 disposed annularly therearound, eachy dened byv the immediately adjacent slots 6i, k8, 10 and 12, etc. The segments 40 are thus connected to the central ordome portion of the liner 2 in acantilever manner and each will independently and resiliently spring fromthe central segment 14 to a degree and without ,material effect on adjacent segments. Froml a Ycomfort standpoint, thel independent spring characteristics of 4the respective segments 40 providethe unique structure'whch readily accommodates or forms the 'entire protective cap to .thehead of a given wearer regardless of his particular cranial contour. `With thisstructure, it has beenffound that a safety cap of the disclosed .arrangement -canv be worn lby a worker for Vextended periods of time without thediscomfort incident toprior art arrangements. The segmented construction of theliner 2 and the resultingfindependent spring actionof the respective seg- -ments 40 also provides Vforthe improved safety efficiency thereof in that the spring action perse tends to absorb and resistaccidenta-l blows to each of the segments 40. Thus, animportant portion of'fthe force from a ,given `accidental blow is absorbed by thel spring action of the cantilever segment 40actually engaged. As noted above, the structure of the plastic liner 2` functions satisfactorily comfort of the safety cap thecushion material 34,

both from the standpoint ofcomfort and safety when the Y slots are formedapproximately two-thirds of the surface distance from the terminal edge 4 of the "liner to' the dome.v`

A further feature of the inthe' appearance thereof but is important froma 'functional standpoint "relates tothe provision of a cloth cover 20 over the entire surface ofthe plastic liner 2. The provision of the cloth cover positively prevents the accidental build-up of` any static electrical chargeonthe liner 2 while inservice. '.Patently,y with the structure shown, the 'liner is continuously "shielded from the frictional charging effectof'moving-jair. 1n thiswconnectiom'itwill be recalled that the`bead 24 aids in preventingv exposure inventionwhich not only aids l of any lpart of the plastic Vliner 2. yAdditionally, in the J preferred embodiment: illustrated, the plastic visor '16 is also completely'covered'with 'the clothmaterial as at 30 D including:

. 4 and 32. Thus, the hazard of accidental spark discharge,

especially in the locale of volatile fuels that was incident to the heretofore employed head safety devices is entirely eliminated.

It is also important to lprovide some ventilation within the cap. The slots 6, 8, 10V and 12 permit this ventilation of the cap even though-the `slots have cushion material 36 over the slots since such cushion material can be of the'open cell type which permits breathing of the ma'- terial, i.e. `flowthrough `of air.

The cap may have the obvious modification of a `noncontinuous domestructure' if the primary protection of the wearer is desired at the side areas of the head; and .the cushioning material mayb'e'circular' strips -inside the cap similar to the :band `38 'but positioned higher'in-the cap extending` crosswiser of the slots.v Y v The invention isfshown by way of illustrationV and'not limitation yand may be subject :to modifications without departing from the scope ofthe appended claims.

1. In a safety cap arrangementr to be worn by auser to -protect the users head'andbeing retained-on theusers head solely by the cap.arrangement,l including:

f (a) a one-piece'lin'er formed'of relatively `hard. and

-resilient plastic` material; said .liner' being permanently molded in 'a vcrown shapegenerally conforming :in configuration to the users head; Y V

`(b.) said'liner having a central section 'located 'at the topof the linerl and positioned on the topfof the Ausers'head;` f j: 'l f1 f (c) .at least vfour cantilever segments `independently 2at tached to andextending Aoutwardly andfdo'wnwardly from saidcentral section,.each segment terminating at a lowerxedge and theflowerl edges of the segments being laterally aligned with each other,'each segment being separated from adjacent segments by ra' narrowslot extending radially of said-liner;

. (d)each of said slots extending atleast about onehalf andilessthan about two-'thirds'the distance from the lower edge ofthe segment to the middleof the central section; 1 H

(e) each of .said `segments being permanently Iformed i f to the lgeneral` shape of the usersf'head in the area 'covered by `the segments; f l.

(f) Eeach segment being resilient Yand"swingable1in.a

a spring action relative tothe central section and relative to eachzother ito 'adapt the liner for-various sizes land shapes Vof usersheads; and said liner being held on `the Vusers `head -solely by .the segments .snugly receiving the users'head; y Y 1 l(g) ya fabric cover Vmaterial intimately encompassing said liner and generally engagedwith the entirelouter n surface tof the liner, the :spring action of said segimentslmaintaining the `fabric cover material taut on the liner, suchthat the 'liner shapes the .fabric cover ,i material, a bead `aflixed'to'the peripheral'edgeay of the `fabricrcover material, and said bead beingirsnappositioned in a'V tensioned conditionbeneath the lower x edges ,ofthe segments `to maintainthe fabric cover material taut on thelin'er.` n i 2.1,Inasafety cap arrangement according to .claim 1 wherein# u..

i (a). atleast eig-htfsegmentsfare independently attached to`and extend .from said central section. 3. In agsafety cap yarrangement according toV claim 1 (a) vat .leastone stud .extendingxoutwardly from. the `lower end ofeach segment,'and, f. `(b) :means .on the fabric. cover material'to `fastenthe l lower Aedge=ofthe cloth coverl materialto each stud. 4. In a safety cap arrangement according to claim y1 includingzf' Y i: 5w v f ,(a) strips of'cushion materiallaxedto theinside of rthe liner and completely overlying said slots. l

(References on following page)V References Cited by the Examiner UNITED STATES PATENTS Weber.

Baier 2 3 5 Turner 2 3 McGuigan 2 185 Brunzell 2 3 Frothingham 2 3 Taylor 2 3 JORDAN FRANKLIN, Primary Examiner. I. R. BOLER, Assistant Examiner. 

1. IN A SAFETY CAP ARRANGEMENT TO BE WORN BY A USER TO PROTECT THE USER''S HEAD AND BEING RETAINED ON THE USER''S HEAD SOLELY BY THE CAP ARRANGEMENT, INCLUDING: (A) A ONE-PIECE LINER FORMED OF RELATIVELY HARD AND RESILIENT PLASTIC MATERIAL SAID LINER BEING PERMANENTLY MOLDED IN A CROWN SHAPE GENERALLY CONFORMING IN CONFIGURATION TO THE USER''S HEAD; (B) SAID LINER HAVING A CENTRAL SECTION LOCATED AT THE TOP OF THE LINER AND POSITIONED ON THE TOP OF THE USER''S HEAD; (C) AT LEAST FOUR CANTILEVER SEGMENTS INDEPENDENTLY ATTACHED TO AND EXTENDING OUTWARDLY AND DOWNWARDLY FROM SAID CENTRAL SECTION, EACH SEGMENT TERMINATING AT A LOWER EDGE AND THE LOWER EDGES OF THE SEGMENTS BEING LATERALLY ALIGNED WITH EACH OTHER, EACH SEGMENT BEING SEPARATED FROM ADJACENT SEGMENTS BY A NARROW SLOT EXTENDING RADIALLY OF SAID LINER; (D) EACH OF SAID SLOTS EXTENDING AT LEAST ABOUT ONEHALF AND LESS THAN ABOUT TWO-THIRDS THE DISTANCE FROM THE LOWER EDGE OF THE SEGMENT TO THE MIDDLE OF THE CENTRAL SECTION; (E) EACH OF SAID SEGMENTS BEING PERMANENTLY FORMED TO THE GENERAL SHAPE OF THE USER''S HEAD IN THE AREA COVERED BY THE SEGMENTS; (F) EACH SEGMENT BEING RESILIENT AND SWINGABLE IN A A SPRING ACTION RELATIVE TO THE CENTRAL SECTION AND RELATIVE TO EACH OTHER TO ADAPT THE LINER FOR VARIOUS SIZES AND SHAPES OF USER''S HEADS, AND SAID LINER BEING HELD ON THE USER''S HEAD SOLELY BY THE SEGMENTS SNUGLY RECEIVING THE USER''S HEAD; (G) A FABRIC COVER MATERIAL INTIMATELY ENCOMPASSING SAID LINER AND GENERALLY ENGAGED WITH THE ENTIRE OUTER SURFACE OF THE LINER, THE SPRING ACTION OF SAID SEGMENTS MAINTAINING THE FABRIC COVER MATERIAL TAUT ON THE LINER, SUCH THAT THE LINER SHAPES THE FABRIC COVER MATERIAL, A BEAD AFFIXED TO THE PERIPHERAL EDGE OF THE FABRIC COVER MATERIAL, AND SAID BEAD BEING SNAPPOSITIONED IN A TENSIONED CONDITION BENEATH THE LOWER EDGES OF THE SEGMENTS TO MAINTAIN THE FABRIC COVER MATERIAL TAUT ON THE LINER. 